Method for preparing a door for installation of a unit lock



June 21, 1966 F. J. RUSSELL ETAL 3,256,918

METHOD FOR PREPARING A DOOR FOR INSTALLATION OF A UNIT LOCK Filed Oct.28, 1963 w W 1 l6 l5 1!" hlilhlii lO '20 1/ 2o y -|I 7 MI IL '[iiMimi-CH2 4| IO f\ 22 \Y 40 5 -4-- IO INVENTORS F250 J- RUSSELL ROGER J2Now/4 AT ORN 5Y5 Patented June 21, 1966 3,256,918 NIETHOD FOR PREPARINGA DOOR FOR INSTALLATION OF A UNIT LOCK Fred J. Russell, 8635 Otis St.,South Gate, Calif., and

Roger J. Nolin, Monterey Park, Calif.; said Nolin assignor to saidRussell Filed Oct. 28, 1963, Ser. No. 319,117 3 Claims. (Cl. 144-326)The invention relates to installation techniques in preparing a door forinstallation of a lock of a particular kind. The lock involved in onewhich customarily is inserted inwardly of the edge of the door,requiring a relatively large cut-out to accommodate the lock casing orhousing.

There is a certain line of locks of a relatively rugged type, with greatsecurity potential, which requires a technique for installation slightlydifferent from the technique and practices employed in the location ofordinary resi-- dential locks. The lock under consideration, althoughknown by various names, consists of a housing substantially as thick asthe door thickness itself and having a length, at and adjoining the dooredge area, which extends a relatively substantial distance from theadjacent edge of the door. Heretofore, the hole made in the door forreception of a lock of the type under consideration was made by sawingtwo parallel saw cuts from the edge of the door and then chiseling outat the inner end between the ends of the two saw cuts in order toaccommodate the inner end of the lock housing. Chiseling, however, is atime-consuming process. Further still, chiseling is rather wasteful ofwood and cannot be done with any great degree of neatness. Furtherstill, when a combination of saw cuts and chiseling is resorted to, morewood is broken away than necessary, and this detracts to an unnecessarydegree from the strength of the door. Although some doors ofconventional construction may lend themselves to a chiseling process,doors with a fine veneer finish are often damaged at the surface in sucha chiseling process, even though the craftsman exercises considerablecare in order not to splinter the surface veneer.

It is among the objects of the invention to provide a new and improvedmethod for preparing a door for the installation of that type of lockwhich is inserted into a notch cut-out in the edge of the door which ispositive, rapid, and also one which assures a neat installation withoutunnecessarily sacrificing the strength of the door.

Another object of the invention is to provide a new and improved methodfor installing that type of lock which installs into a notch cut-out inthe edge face of the door which may be limited to three rapid directoperations, namely, the boring of a hole and the making of two cuts fromthe edge'of the door to the edge of the hole, thereby to prepare thedoor for installation of the lock.

Another object of the invention is to provide a new and improved methodfor preparing a door for installation of that type of lock whichinstalls into a notch cutout in the edge faces of the door which reducesthe time required to cut the back end of the notch, which makes possiblea much more rapid installation of the lock in the door, and also onewhich gives great assurance of a neat door cut-out.

With these and other objects in view, the invention consists in thearrangement and combination of the various aspects of the method,whereby the objects contemplated are attained, as hereinafter set forthand pointed out in the appended claims and illustrated in theaccompanying drawings.

In the drawings:

FIGURE 1 shows a'fragmentary side elevational view of a door with theinitial operation completed.

FIGURE 2 is an exploded view showing in part a:

fragmentary side elevation of the door with the door completed forinstallation of'a lock housing, and such a lock housing in a positionready for insertion.

FIGURE 3 is a fragmentary side elevational view of a door with the lockhousing in place.

FIGURE 4 is a cross-sectional view taken on the line 44 of FIGURE 2.

FIGURE 5 is a fragmentary side elevational view of the door with a notchcut-out slightly different from the cutout of FIGURE 2.

FIGURE 6 is a fragmentary side elevational view of a door similar toFIGURE 5 but showing a third manner of making an appropriate cutout.

In an embodiment of the invention chosen for the purpose ofillustration, there is shown a door 10 having a free or swinging edge 11and possessed of opposite faces 12 and 13. The method here underconsideration is one adapted to prepare the door 10 for installation ofa lock housing like the lock housing indicated generally by thereference character 15. In the form of lock housing illustrated, thehousing consists of parallel upper and lower edges 16 and 17,respectively, extending inwardly to an area of substantial tangency to arounded inside end 18. Ordinarily, in order to take greatest advantageof the method here involved, the inside end is semi-circular I and madeto a radius equal to substantially half the distance between theparallel upper and lower edges 16 and 17. Although not expresslyillustrated in the drawing, the thickness of the housing 15 issubstantially the some slight variation from the expressed exemplarydimensions may be encountered while falling within the invention hereindisclosed. The knob, spindles, and escutcheon plates of the lock areconventional and are not shown. Generally, the escutcheon plates clampthe faces 12 and 13.0f the door 10 and overlap all areas of the doorcut-out to the left of a ridge 19 of the lock as identified in FIGURE 2.i

To make the desired cut-out, a hole 20 is located at a distance inwardlyfrom the edge 11 such that the hole will provide a free fit for therounded inside end 18 of the lock when the lock housing is in properposition in the door. Although the clearance need not be great, it isbest to have a clearance which will offer no impediment to the fullinsertion of the lock housing when it is fitted into position from theedge of the door. I

After the hole 20 is neatly bored through the door, preferably in partinward from the face 12 and in part inward from the face. 13 to avoidsplintering, cuts are made inwardly from the edge 11. An upper cutresulting in an upper inside edge 21 is spaced from a lower cutultimately forming a lower inside edge 22 by a distance substantiallyequal to the distance between the upper and lower edges 16 and 17 of thelock, or very slightly greater. These cuts are then extended inwardlyuntil they join respectively upper and lower edges of the hole 20. Wherethe hole 20 is slightly greater in diameter than the distance betweenthe inside edges 21 and 22, the saw cuts will entirely loosen theportion of door-material there- 1 between, which then can be readilyremoved without effort. In this instance also, inasmuch as the diameterof and 17 respectively with the upper inside edge 21 and the lowerinside edge 22 will be depended upon to snugly and accurately positionthe lock housing in the notch thus formed.

Further still, by reason of carefully locating the hole at a properdistance inwardly from the edge 11, an end face 23 of the lock housing15 can be brought precisely flush with the end edge 11 of the door,while still permitting a space 24 remaining between the inside end 18 ofthe lock and the innermost surface of the hole 20.

In the form of invention in FIGURE 5, slightly greater accuracy isrequired in the operation in that the diameter of a hole is madesubstantially the same as the distance between an upper inside edge 31and a lower inside edge 32. In this example, the saw cuts, whichaccomplish respectively the forming of the upper and lower inside edges31 and 32, are spaced apart a distance substantially equal to thediameter of the hole 30 and are aligned precisely with the upper edge 33and the lower edge 34. This usually means a snugger fit therein of thelock housing 15, but by spacing a center 36 of the hole 30 inwardly farenough, a clearance still will be provided between most of an arcuateportion of the hole 30 and the inside rounded end 18 of the lock housing15.

In still another form of the invention illustrated in FIGURE 6, it maybe assumed that an inside rounded end similar to the end 18 of the lockhousing 15 has a slightly different configuration or that the spacingbetween parallel upper and lower edges 16 and 17 is slightly greater. Inthis instance, a hole 40 is bored with its center 41 spaced a desireddistance inwardly from the edge 11 of the door 10. Here again, thespacing of parallel upper and lower saw cuts resulting in the productionof a parallel upper edge 42 and a parallel lower edge 43 should be suchas to provide a substantially snug fit between corresponding upper andlower parallel edges of the appropriate lock housing. When the saw cutsfrom the edge 11 are made for this form of device, they will neverprecisely cut through into the hole 40. The cuts, however, may beextended to points 44 and 45 through a location almost or substantiallyopposite the upper and lower extremities of the hole 40. By bringing thecuts inward to this point, wood material of the door 10 will be weakenedsuificiently so that the wood material can be knocked loose, breakingthe small remaining thicknesses of material between the points 44 and 45and the wall of the hole 40. Since lock housings of the kind undercorisideration invariably employ escutcheons to overlap the faces of thedoor, the presence of broken material at the points 44 and 45 will notbe detrimental to the appearance of the installation after it has beencompleted, for they will be covered up by the escutcheons.

It will be appreciated that the installation method can be accomplishedwith substantially a minimum number of operations, namely, a simpletransverse boring operation'followed by two saw cuts which can easily belocated at the swinging edge 11 of the door.

While the invention has herein been shown and described in what isconceived to be the most practical and preferred embodiment, it isrecognized that departures may be made therefrom within the scope of theinvention, which is not to be limited to the details disclosed hereinbut is to be accorded the full scope of the claims so as to embrace anyand all equivalent methods.

Having described the invention, what is claimed as new in support ofLetters Patent is:

1. A method of preparing a door at an edge for the installation of alock of the type which installs in acutout notch at said edge, saidmethod comprising locating a hole of selected radius at least as largeas the inside end of said lock, boring said hole through the door fromone face to the other, making two plane face cuts through said doorinwardly from said edge with the plane faces of the cuts parallel toeach other throughout the length thereof and spaced from each other adistance equal to the diameter of said hole and approximately the sameas the distance between said parallel upper and lower edges of the lock,whereby to provide a snug fit for the upper and lower edges of saidlock, continuing making said cuts until both said cuts substantiallymeet respectively upper and lower edges of said hole and form lines ofjunction with said hole parallel to said plane faces and to each other,and then removing door material defined by said hole and said cuts.

2. A method of preparing a door at an edge for the installation of alock of the type which installs in a cutout notch at said one edgewherein the lock has an inside rounded end and substantially parallelupper and lower edges, said method comprising locating a hole slightlylarger than said rounded end and having a diameter between one half andtwice the thickness of the door, boring said hole through the door fromone face to the other whereby to provide a free fit for said roundedend, making two plane face cuts parallel to each other through said doorinwardly from said edge with the cuts spaced from each other a distanceequal to the diameter of said hole and substantially the same as thedistance between said parallel upper and lower edges of the lock at itsdoor edge end, whereby to provide a snug fit for said upper and loweredges, continuing making said cuts until both said cuts substantiallymeet respectively upper and lower edges of said hole, and then removingdoor material released by said cuts.

3. A method of preparing a door at an edge thereof for the installationof a lock of the type which installs in a cut-out notch at said edgewherein the lock has an inside end which will fit within a selectedradius and has substantially parallel upper and lower edges at its dooredge end, said method comprising locating a hole of said selected radiusat a distance inwardly from said edge, boring said hole through the doorfrom one face to the other whereby to provide a free fit for said insideend, making a first cut through said door progressively inwardly fromsaid edge and then making a second cut through said door progressivelyinwardly from said edge and parallel to the first cut, said cuts beingspaced from each other a distance only slightly greater than thediameter of said hole and approximately the distance between saidparallel upper and lower edges of the lock, whereby to provide a snugfit for said upper and lower edges, continuing making said cuts'untilboth said cuts substantially meet respectively upper and lower edges ofsaid hole, and then removing door material released by said cuts.

References Cited by the Examiner UNITED STATES PATENTS 1,080,073 12/1913 Morehouse 14435 2,356,046 8/1944 Garlick 93l 2,790,470 4/ 1957Graham 14427 2,814,219 11/1957 Zern 144-27 HAROLD D. WHITEHEAD, PrimaryExaminer.

WILLIAM W. DYER, ]R., Examiner.

1. A METHOD OF PREPARING A DOOR AT AN EDGE FOR THE INSTALLATION OF ALOCK OF THE TYPE WHICH INSTALLS IN A CUTOUT NOTCH AT SAID EDGE, SAIDMETHOD COMPRISING LOCATING A HOLE OF SELECTED RADIUS AT LEAST AS LARGEAS THE INSIDE END OF SAID LOCK, BORING SAID HOLE THROUGH THE DOOR FROMONE FACE TO THE OTHER, MAKING TWO PLANE FACE CUTS THROUGH SAID DOORINWARDLY FROM SAID EDGE WITH THE PLANE FACES OF THYE CUTS PARALLEL TOEACH OTHER THROUGHOUT THE LENGTH THEREOF AND SPACED FROM EACH OTHER ADISTANCE EQUAL TO THE DIAMETER OF SAID HOLE AND APPROXIMATELY THE SAMEAS THE DISTANCE BETWEEN SAID PARALLEL UPPER AND LOWER EDGES OF THE LOCK,WHEREBY TO PROVIDE A SNUG FIT FOR THE UPPER AND LOWER EDGES OF SAIDLOCK, CONTINUING MAKING SAID